Modeling of a continuous rotary reactor for carbon nanotube synthesis by catalytic chemical vapor deposition

The modeling of carbon nanotube production by the CCVD process in a continuous rotary reactor with mobile bed was performed according to a rigorous chemical reaction engineering approach. The geometric, hydrodynamic, physical and physicochemical factors governing the process were analyzed in order to establish the reactor equations. While the study of the hydrodynamic factor suggests a co-current plug-flow approximation, the physical factor mainly deals with the phenomena of transport and the transfer of mass, which can be neglected. Concerning the physicochemical factor, the modeling is based on knowledge of the expression of the initial reaction rate, and takes into account catalytic deactivation as a function of time, according to a sigmoid decreasing law. The reactor modeling allows obtaining the evolution of partial pressure, carbon nanotube production and catalytic deactivation along the reactor for given initial operating conditions. The comparison between experimental and calculated production highlights a very good fit of data. (c) 2009 American Institute of Chemical lEngineers AIChE J, 55: 675-686, 2009